Tunnel kiln



0.ct.21, 193.0. O.,L,BARNEBEY ET'AL 1,778,747

Filed` Feb. 2l, 1925 3 SheetS-Sheet -2 ALUNDUM COOLING TUBES.

ocr. ai', 1930 UNITED STATES OSCAR yI.. BARNEBEY, OF COLUMBUS, AND MERRITT B. CHENEY, DECEASED, LATE OF BRIGGSDALE, OHIO, BY JOSEPHINE B. CHENEY, ADMINISTRATBIX, OF BRIGGSDALE,

OHIO

TUNNEL KILN Application led February 21, 1925i.y Serial No. 10,925.

This application is in part a division of our application, Ser. No. 283,639, filed March 19, 1919, which has issued into U. S. Patent No. 1,541,099;

5V This invention relates to an apparatus Jfor carrying out chemical reactions at high temperature and other treatments of materialfat elevated temperatures. The invention has special reference to an apparatus for the activation of carbon and carbonaceous material. Heretofore carbon has been activated by treatment with steam in vertical tubes made of nichrome alloy, such tubes being about seven inches in diameter and heated externally. Steam is introduced into the charcoal in this tube through an inner tubeat the temperature of operation, approximately 900O C. Reaction of the steam on the charcoal produces what is known as.activ'ated charcoal.- Other furnaces, suchas require the use of a revolving tubev or the use of an inclined hearth have been proposedfor steam activation.

The vertical seven vinch treater has a very which it possesses requires the conduction of heat through the carbon, which is highly insulating in character, to a depth too great to be practicable. This treater has a serious disadvantage of having the essential parts made of metal which deteriorates rather rapidly.` The use of the revolving tube which is also 1nade-oimetal introduces the same objections as 'the vertical treater when the tube is filled with any considerable depth of mavterial and unless it is thus iilled the output of such a tube is so small that it becomes impracticable. Furthermore, such a revolving furnace has the disadvantage of having avery tratewithin the practical depths at which it must be operated. Inclined hearth furnaces have the disadvantage of requiring the layers of carbon on the hearth to be uneven in thickness and further are difiicult to regulate. Although inclined furnaces of this type have been proposed they have not been reduced to practice.

In the three furnaces mentioned above the movement of the carbon in the process prolimited capacity and to utilize the capacitydeep layer for the activating gases to pene-v duces more or.less abrasive eect on the carbon during activation, thus exerting a grindlng etfect on the charcoal and producing an excessive quantity ot' fines which in certain cases is objectionable.

Among .the objects of this invention is to provide an apparatus whereby carbon or other material may be treated at high temperatures with reactive as well as non-reactive gases. A further object oi this invention is to provide an apparatus whereby large quantitiesof carbon or other material may be given a high temperature treatment and whereby the process may be effectively carriedv out'in a comparatively short time. A still further object of this-invention is to provide an apparatus whereby the temperatures at all stages of the device may be closely controlled and regulated and, more particularly, permita gradual gradient of temperature from each end of the device toward the central portion-having the highest temperature.

More specifically, it is an object of this invention to provide anapparatus whereby carbon or carbonaceous material may be treatedwith oxygenated gases at temperatures upto 1300O C., and whereby these heated oXygenat-ed gases are allowedlto penetrate and come in contact with all portions of the masses of carbon or carbonaceous material undergoing treatment.

Other Afurther and more speciic objects of the invention' will become readily apparent to `persons skilled in the art from a consideration o the following description when taken inl conjunction with the drawings, wherein Fig. l is a longitudinal cross-section offa portion of the device embodying the front end of a kiln.

Fig'. 2 is a side elevation of another portion of the device embodying the rear end 'of the kiln, a portion of the device being broken away to illustrate the interior thereof. i

Fig. 3 is a transverse cross-section through the kiln in the region of the burners.

Fig. 4 is a transversel cross-section `through the kiln in the region of the side water sprays.v f

Fig. 5 is a fragmental View partly in seetion showing a carrier with stacks of saggers or trays in the interior of the kiln.

Fig. 5 is a perspective view showing one of our preferred forms of trays, preferably made of ceramic material, and containing` the carhon or charcoal to be treated in the kiln.

Figs. 7 and S are horizontal crosssectional views taken at the front and rear ends, respectively, of the kiln.

Fig. l) a horizontal cross-sectional view ofh portion of the kiln intermediate between the ends and taken in the region of the burners and illustrating a modified form of heatingy arrangement.

The apparatus comprises a kiln having' a long tunnel and provided with a pair of rails (1) for conveying cars (2) carrying stacks of sauger-s (f3) for receiving the material to he activated. .llt cach end of the tunnel is a vestihule (l) proyidee with an inner doorl (5) and an outer door (il). rthe inner door (3) is prefer-abi).Y :.:onstructed of asbestos with suitable metal braces and supports and moves vertically in guide-ways which are made gastight h v suitable metal casinos. .l counter weight (tl) is arranged in the manner shown, and assists in raising and 'lowering the door (5). 'lhe outer door (G) is similarly constructed and disposed and moves in guideavays (9). in order to secure a. 1eas-tight closure for the outer door, so as to Vprevent gases from escaping from or en` tering the tunnel, a pair of wedges (10) are arranged at the sides of this door and another pair at the lower corners. The guides w ys are provided with inclined abutments for receiving' these wedges. so that when the door is lowered it automatically lits itself securely against trie framework.

y'llhrouejhout its entire length the tunnel is divided horizontally into an upper and lower compartment. rhe upper coimgartinent conta ins the stacks of sae'gers with charcoal and ib 25h it the hot rc; ses are passed fo actii yThe lower compartment contains cooling tubes (ll) through whiclrair or water may he passed in order to keep the metal parts ofthe trucks cool. lf the air is not sullieieni. for this cooling` purpose. additional water itipes may he supplied for furnishingl cooling media for the lower truck frames. f'tfter i air or water leaves these tubes it may e passed into the con'lhustion. chamer or into the front end ofthe tunnel for ditreatn'ient of the carbon or charcoal. VVietween these two compartiments are arranged a. pair of projectingrledges (12), which make close Contact with the sides of he cars so that when the tunnel is entirely L"'lled with ca there will be very little coinnuinication hetweer the upper and the lower compartments. isis necessary in order to keep the two compartments at widely different temperatures.

rllhe air and fuel are introdueed'hy means4 of burners (1l) located at the central portion of the furnace. rEhe air-fuel mixture conducted to the burners by the manifolds (1lb), the individual burners being regulated hy`valvcs (14"). Combustion preferably occurs in a. pair of combustion chambers arranged alone the sides of the furnace7 but modilications thereof, for eitarpple as shown in Fig. 9 where the c0mhustion occurs in separate chambers (15) which are walled away from the inner Zone, may also be used. ln this latter construction the gases heat the walls, which commu? nicate the heat to the inner Zone.v

'.l`he `.grasos pass from the combustion chambers through the upper compartment of the furnace and are lirst removed through a stack, and if desired may be laused to reenter the .riln lhroiugl pipey (1G). llt the point where the hot rias reenter the kiln they arehiixod with iets ol' wate steam or carbon dioxide issuing from the noir/,les (lil). which arecontrolled by the valves (15)). These nozzles arc directed into the heated furnace gases so as to insure in mediale vaporization of the water when w: er in lhe'liduid phase is cmployed. lin us a hurner system, such as illustrated in 'lfif` Il. il is not necessary lo add combustion gases through pipe (1G), but the atomized water or steam is added in this case through the nozzles (15%). lifter pas ing' through the tunnel trono the ear exit 15o the car intake end. the rases are led out by way of chimneys (720).

rThe'car for .carrying the trays with the. material ,r,ins-:i::l':y ol a metal truc/l' and a lire-brick siipenstruclure (22), upper portion of which a n mher of'gljas nea r the i passages (223) are. provided whicl open into a central 'ludinal opening' (2l). rl`he trays are a rrangfcd in vertical stacks super imposed upon and si tly spaccd from early other .L as to perm rculation ol gases on all sides and lahrally llicrmhrolul'h. rlfhe position of the car in the vestibule may he. controlled by a hooked rod (25) which ma]v -be passed through an opening; in the outer -are provided at the exit end of the kiln and loo llo

also at intermediate points thereof so that water or gas may be introduced Wherever and in whatever position desired. At the car exit end of the kiln the Water or steam cools the cars and material carried therein, thus preparing same for exit from the kiln.'

' The burners '(14) which may be fedwith either solid, liquid or gaseous fuel are direct"-A ed inward and downward against beds of alundiim chips (14C) which are, arranged between the outer furnace walls and the tunnel. The inner wall of the tunnel comprises the vertical walls (29a) and the curved or sloped continuations (29".) cxtmi from the vertical walls (29a). These W ls and continuations serve to direct the products of combustion from the combustion chambers v(1.5) into and" through the layers or masses :of material in the saggers (3) and thus prof atmospheric air.

lighter.

mote uniform heating of the stacks of saggers from the bottom to top.

At the eXtreme front end ofthe tunnel are provided two chambers (30), one -at each side of the tunnel, for receiving the exitV gases. From these chambers the exit .gases mav be discharged to any other desired pla-ce.

The walls (3l) and (32) of the end compartments are preferably of fire-brick material and constructed so as to be substantially 'air-tight and lit snugly into the door jambs` of Vdoors (G and 7) which connect the intake and exit chambers to the interior of the furnace and close the ends of the furnace to The inside of the walls (33) of the main portion of the furnace are constructed of high grade tirebrick and the crown (34) of the furnace is constructed of tire-brick. i i vWater or steam sprays (35) controlled by valves (36) (illustrated in`Fig. fl) are used in any part of the furnace which tends to develop local hot spots, so that the temperature at such )ortions may be reduced to that required. T iese water atomizers or injectors also serve to supply the desired quantity of water vapors at any point in the c0nduction of the process. l i

The port (3T) serves as an entrance to the beds of alundum chips (llc). The pipe connects to port (37) and is provided with a cap (39) having a portion (40) of glass or isinglass, thus affording a` vision directly into the furnace while avoiding the entrance of air. These fittings also provide a meansV ,for lighting the furnace, which canbe .done

b v removing the cap (39) and inserting a Upon opening the valve (14a) the air-fuel mixture will enter the furnace and be lighted and burn on the beds of alundum chips (14C) after which the lighter is withdrawn and the cap (39) screwed into place.

It is to be understood that in this specific embodiment as well as in the modifications thereof falling within the scope of this in* ventior. that suitable provisions may bemade of the furnace.

for receiving pyrometers, manometers and fother gas testers, such as are present on furnaces, these forming no part ofthe present invention.

The exterior housing for the doors (G) and l (7), illustrated in Figs. 3 and 4 comprises the casing (4:1) above which is a` heavy supporting member (42), suclias an angle iron l(a5) and. (46) and supports the dead weight (8) at one end and connects with the doors (6) or (7)-,at the other. This facilitates the lraising and lowering of the door within the furnace. The framework and exterior hous ing are made of heavy metal riveted or bolted'securely together, thus making the entire enclosure air-tight except wherethe rope (44) passes through opening (a3), and a stuffing box may be used at the opening (43) if def sired.

Ordinarily, the length of tunnel is 200 to lOO feet whichprovides for a preliminary heating zone of 5() to 100 feet, an activating zone of 8O to l5() feet and a cooling zone of 70 to 150 feet. A width of S to l5 feet and a` height of 7 to 12ffeet will' satisfy the ordinary needs for `carbon activation. The

trucks shouldV preferablybe of such dimensions that at least one may be conveniently placed in the front and rearvestibules when stacked with saggers as illustrated 4in the drawings and also reach close to the sides of the projecting ledges (12) of the tunnel.

In carrying out a process, for example the activation of charcoal 0i' carbon, with this apparatus, the proportions of heating and activating gases used may be varied through a considerable If carbon dioxide is to be used, the cheapest'sourcc of supply is the combustion gases resulting from operating the furnace. vIn using water for activation or cooling it may be introduced into the furnace by either .'atomizing or spraying, as water or as vsteam or super-heated stem.

Advantages may be derived from using a recuperative system at eitheror both ends Counter-current movement of gases and cars gives recuperation. By injecting water or steam so as to reach the maferial undergoing treatment before exit from the furnace, the` material and lcontainers will be cooled before leavingthe kiln. 'By adding water in this matter, a much nore uniform temperature gradient can` be obtained throughout the reactive region of the furnace.

Combinationsof the effects heretofore' described may be used to advantage. For inor more intakes or hurncrs.

through in a` direction substantially parallel to that of the moving cars or furnace bottom, thus accomplishing two desirable results; that is, heatingathe cars and Jfurnishing` carhon dioxide and steam (it hydrocarbons are hurned as fuel) for activation. It the turnace is very long7 the gases from the com hustion'chamher may he too cool to heat up the cars as they enter, hut may he used to cool the cars at the exit end of the furnace and to jt'urnish cai-hon dioxide or steam tor activation, or either of these objects may "ec accomplished.

The heat. may he produced h v combustion ot solid fuel, such as coal, either lump or powdered; h v combustion et liquid ituel such as oil` continuously supplied als a stream ot liquid. sprayed or atomized; or h v the hurning ot gaseous t'uel such as natu al gas, water producer gas. cte. The. fuel may he hand or machinery stoked. injected hy air blast, or supplied in anvothcr'coiivenient manner. ltmay he added to the turnace through one A. long` continuous combustion chamher or a series oit shorter chamhers may he used tor burning the tuel in supplying the heat. Connections may he made directly from the combustion chamhcr to the reaction chamlier so that, the reaction gases may in whole or in part move directly into the reaction chamber. ln. "tact, there need not necessarily he separate comhustion and reaction cha mhcrs in the turnace Iii as shown in Figs. 5 and 9. i wall may only parriall separate the two in such a manner as to give for all intents and purposes a iiniforn'i l Furnace in which occurs the com- Yn oft the tuel and the treatment ot the Ycrial 'with reactive gas. The wall.

:'v. can he cfnnpletelv removed and t @installation he so adjusted that 'tl i itire das can he heated to the proper teni-- turc activation. Especially is this use ot surface or liameless comtor the hust-Eon.

miur arrangement of layers of material in fle st'aclts with intervening spaces liei'cen the layers has man;Y advantages over a single laver. ln tact. without eature this invention .wouldiori'linarily i ',diminished or little value. llv this construction the flow of gases in horizontal dircc- Vtion is ``plity into a multitude ol` horiz/.ontal streams which give rapid heat transfer. apid exchange ot oxygenalcd gases te and 'rom the material and further torccs the gases ro tl i n iaterial through the narrow passages formed hctivecn the layers. rThis is very ditlicult ro accomplish in a single laver. Still further. the multiple layers malte possible a large production output v'from the furnace7 which is not possihle with a single layer process.

The layers ol1 carhon are prelerahly from to 2 :inches in depth, although layers 3 the i inches deep may be employed. As the depth of these layers increases above S/L inch the length of time required ,tor the treatment is proportionately increased and when this depth is greater than three inches the qualitj.' ot` the product is interior and :r much longer time is required to produce .carbon ot even medium activity. lVhere the. term thin employed, it is intended to cover layers ot .this character, not exceeding three inches in thickness.

rlhe carbonaccous material in the layers is ordinarily in granular form. To obtain this granulation, the material. is usually inilvcr` .ized and then screened to l-14 mesh. 'l'hc layers of material are moved or conducted through the furnace upon the carriers. and the carhon is thus moved en masse and remains in a, quiescent condition throughout the treatment; that is. the granules Awithin a layer are substantially without interinotioin-thus avoiding the rul'ihing and grinding ellfcctns incident te the operation liy means of the prior types olf furnaces hereto'lore dcscriliied. It is preferable to have the layers ol uniform thickness and spaced from each other a distance of 'lV/,fl inch. Greater separation of the layers is to he avoided due to wastage of the liiln space and reduction in capacity of the furnace. The thin layers not only allow the reactive to penetrate therethrough hut also promote uniform heating of the mass and permit raad): escape o'l` the gaseous reactionproducts.

"llhe ceramic saggers arc stacked in multiple .series on cars which are moved through the lfurnace in such a manner as to leave between the sides and ends of the saugt-rs as vir l as hetA ken the sa ers superimposed on. each other in order i l: thorough cir-cuon ot' the reactive gases. i

[he material emiiloycd Ain this amiaratir-a it'or producing activated carhon is carhonaccous' material hv which term it .is intcnflei'l te, include charcoal anthracite coal. liituminous coal. .vood7 vegetable nuts? lamp lilacl,

hone hlaclt, oil shale and other carhon con taining materials. hoth natural and artilicial.

rthe time et activating the material varies with the nature ot source of the material licing1 treated, i. e., cocoanut cai-hon may require two hours at ST5@ or ten hours at StltlJl (l. Natural coal may ,equire live hours at 875@ C. or twenty hours at SOOO C. operating with inch layers et granular material. "lilith deeper layers ot materiah longer periods o time are required to accomplish the same remsults. The time of reaction is sullicieiitlv pro- "ionged to ohtain the maximum actiii'ation without undue losses of material.

The equipment can he operated at anv teinperature desired. Using our system (it distributing hurncrs along the sides of the turnacc any temperature can he maintained at any particular position of furnace length.

sa 1a ce Further our system of cooling accomplishes the cooling in a much shorter length of furnace than any other furnace of the movable bottom type, thus greatly lowering the cost of construction and giving greater capacity per unit of furnace length The control of furnace conditions is made much better than previous furnaces of this type by the special method of burner arrangement and by vour methods of cooling'.`

The entire operation is performed With the gases under* only such pressures as are normally produced in the particular furnaces by the injection of the combustion gases and steam and the regulation of fine conditions of the furnace. No special attempt is made to produce abnormal pressures or evacuation. But it is preferable to have the furnace under slight positive pressure in order to insure a uniform gas atmosphere existing' throughout the furnace. The manner of using the apparatus may be varied Widely, depending up on the conditions of temperature, pressure, composition ofreactive gases, and material Within the furnace.

The present invention is not limited to the specific details set forth in the foregoing eX- amples which should be construed as illustrative and not by Way of limitation, and in veW of the numerous modifications Which may be effected therein Without departing from the spirit and scope of this invention, it

'is desired that only such limitations be imposed as are indicated in the appended claims.

lVe claim as our invention: y l. A tunnel kiln comprising a lower com- 'partment having cooling means and-'an upper compartment having entrances through the side for delivering into the kiln at the central portion and at points intermediate the central portion and each end of the kiln heating and reacting gases and producing gradual gradient of temperature from each end of the kiln to the central portion of highest temperature, said lower compartment being provided With a track for supporting and guiding a movable carrier througlrthe kiln, a separating member for effecting substantial separation of the upper heating compa rt'- ment from the lower cooling compartment When the tunnel is filled with carriers and means for atomizing Water into the exit end of the upper compartment of said kiln.

2. tunnel kiln comprising a lower compartment having cooling means und an upper compartment having entrances through the side thereof for delivering into the kiln at the central portion and at points intermediate the central portion and each end of the kiln heating, reacting and cooling ,gases and producing gradual gradient of temperature from each end of the kiln to the central portion of highest temperature, a separating member for effecting substantial separation of the upper heating compartment from'the lower cooling compartment When the tunnel is filled with carriers and means for regulating the return to the kiln of the gases exiting therefrom.

3. A tunnel kiln comprising a lower compartment having cooling means, and an upper compartment having adjustable supplies, of heating, cooling and reactive fluid distributed therein at the. Central portion and at points ini kiln comprising an upper compartment having heating means at the central portion and at points intermediate the central portion and each end of the kiln for producing gradual gradient of temperature from each end of the kiln to the central portion of highest temperature and means for delivering reacting gases, and a loiver compartment having cooling means, means for atomizing Water into the exit end'of the upper compartment of said kiln, a carrier having a plurality of superimposed trays for holding the material to be treated, said superimposed trays forming an open-Work structure permitting free circulation of activating` gas between same, means comprising rollers supporting said carrier for effecting smooth travel of said carrier through the kiln,',and a separating member for effecting substantial separation of the upper heating compartment from-theloiver cooling compartment when the tunnel is filled with carriers'.

5. In an apparatus for activatingcarbon, a tunnel kiln having .a preliminary heating zone leading from one end of the kiln to an activation 'zione in the iiltermediate portion of the kiln and a cooling zone leading from the intern'iediate portion' of the kiln to the other 'end of said. kiln and adjustable supplies of heating, cooling and activ-ating fluid distributed throughout said kiln at the central portion and at points intermediate the central portion and each end of the kiln for regulating and controlling the temperature and activation of the carbon With-in said kiln and producing gradual gradient of temperature from each end of the kilnto the central portion of higlest temperature, and means for aton'iizing Water into the exit end of the upper compartment of said kiln.

G. In an apparatus for activating carbon, a tunnel kiln having a preliminary heating zone leading from one end of the kiln` to an activation zone in the intermediate portion of the kiln and a cooling zone leading from the lating the ieturn to the kiln of the gases exiting therefrom.

7. In an apparatus toi' activating carbon, a tunnel kiln having means for producing gradual gradient ot teii'iperature troni each end of the kiln` to tlie central portion of highest temperature, said means comprising a preliminary heating'zone leading from one end of the kiln to an` activation zone` in the intermediate portion of the kiln, a cooling. zone leading from the intermediate portion otv the kiln to the other end or' said kiln and adjustable supplies ot heating, cooling and activating fluid distributed throughout said kiln at the central portion and at points interinediate the central portion and each end of the kiln for regulating and controlling the temperature and activation of the carbon within said kiln, means for atoinizng Water into the exit end of the upper compartment ot said kiln, and a substantially airtight vestibule adjacent to an end of said kiln and adapted to hold a movable carrier supporting a plurality of trays.

8. A tunnel kiln comprising a lower compartment having cooling means and an upper compartment having adjustable supplies of heating, cooling and reactive fluid distributed therein at the central portion and at points intermediate the central portieri` and each end of the kiln for positivelyv holding the temperature substantially uniform throughout the central portion of highest temperature and for regulating and controlling the temperature and the reaction at -each stage of the kiln and producing gradual gradiant of temperature from each end of the kiln to the eentrol portion of highest temperature, means for atomizing Water into the exit endof the upper compartment of said kiln and means for regulating the return to the kiln of the gases exiting therefrom.

9. In an apparatus for activating carbon,

a tunnel kiln comprising a lower compartment having cooling means and an upper' compartment having adjustable supplies of heating, cooling Vand activating Huid distributed therein at the central portion and at points intermediate the central ortion and each end of the kiln for holding t e temperature substantially uniformi throughout the central portion vof highest temperature and for regulating and controlling the temper ture and activation at each stage of the kiln waage? and producing progressive' heating and cooling zones extending from the ends of the carbon activating Zone ot highest teinperature, means itor atomizing Water into the exit end of the upper compartment of said kiln and means for regulating the return to the kiln ot the gases exiting therefrom, a carrier having a plurality ot' superimposed trays forming an open-Work structure perinittiiig free circulation of activating gas between saine, and means comprising a track in said lower eempartment and rollers` supporting said carrier for effecting smooth travel of said carrier throughout the kiln.

OSCAR L. BARNEBEY. g JOSEPHINE B. CHENEY, Admz'm'stmtrz of the Estate of Merritt L.

Cheney, Deceased. 

